Polishing tool

ABSTRACT

An apparatus for polishing a surface comprising: a polishing head comprising a plurality of flap assemblies; and a shaft attached to the plurality of flap assemblies for rotatably driving the polishing head.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/029,059, filed on Feb. 15, 2008, and U.S. Provisional Application No.61/048,019, filed on Apr. 25, 2008, which are incorporated herein byreference.

FIELD OF THE INVENTION

The present application relates to a rotary tool for polishing asurface.

BACKGROUND OF THE INVENTION

Rotary polishing tools are available for polishing various surfaces.Such tools commonly have a substantially uniform size and shape makingit difficult for a single polishing head to polish surfaces havingvarying sizes and shapes. For example, U.S. Pat. No. 7,203,989 B2,discloses a buffing and polishing ball made of a compressible polymericfoam material is formed by slitting a body of foam material in asubstantially uncompressed state (1) from an outside surface of the bodyin a direction generally perpendicular to the rotational axis and (2) oncircumferentially spaced planes that extend generally radially from theoutside surface of the body to define a plurality of foam fingers. Afastening system is used to compress and hold a center portion of thefoam body in a direction along the rotational axis such that theuncompressed outer ends of the finger assume a generally spherical ball.

In addition, U.S. Pat. No. 5,560,744 discloses a buffing apparatusincluding a buffing assembly including a stack of buffing wheels with orwithout spacers between the rings, compressed under high pressure. Eachwheel includes a clinch ring which in turn secures an annulus of fabricextending radially therefrom. Each spacer includes a ring; they may bethe remnants of used buffing wheels. The wheels and spacers, if any, arecontiguous forming an inner cylindrical surface of the rings. Steelstraps extend axially along this inner surface, the straps being securedby metal inert-gas welding to the rings at the ends of the stack. Thepressure between the buffing wheels and any spacers of the stacks is sohigh as to suppress any tendency of the wheels or spacers to slipcircumferentially with respect to each other when the stack is underhigh tangential force in use. The straps serve to be engaged by the keysof a drive shaft to drive the buffing apparatus.

Such shapes are not generally suitable for polishing small cavities aswell as large substantially flat surfaces.

SUMMARY OF THE INVENTION

In one embodiment, the present invention provides an apparatus forpolishing a surface comprising: a polishing head comprising a pluralityof flap assemblies; and a shaft attached to the plurality of flapassemblies for rotatably driving the polishing head.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed understanding of embodiments of the present invention,reference is made to the following detailed description of exampleembodiments, taken in conjunction with the accompanying drawings, inwhich like elements have been given like numerals, wherein:

FIG. 1 is a view of an example embodiment of a polishing tool forpolishing a surface;

FIG. 2 is a view of another example embodiment of a polishing tool forpolishing a surface;

FIG. 3A is a view of an example of a polishing head;

FIG. 3B is a cross-section of the polishing head of FIG. 3A;

FIG. 4 is an exploded view of an example of upper and lower materiallayers with at least one stiffener element between the upper and lowermaterial layers;

FIG. 5 is a cross-section of a flap assembly showing upper and lowermaterial layers with stiffener elements;

FIG. 6 is a cross-section of a plurality of stacked flap assemblies;

FIG. 7 is a view of another shape for a material layer;

FIG. 8A is a view of an example of a material layer having asubstantially circular bulbous tip;

FIG. 8B is a view of substantially elliptical bulbous tip;

FIG. 9A is an exploded view of one example of a flap assembly;

FIG. 9B is a view of the assembled flap assembly of FIG. 9A;

FIG. 10 is a view of another flap assembly;

FIG. 11 is a view of one example of a flap material layer having atextured surface; and

FIG. 12 is a view of another example of a flap material layer having atextured surface.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, in one example embodiment, a polishing tool 10comprises a polishing head 20 coupled to a handle assembly 30. Polishingtool 10 may be coupled to a rotary power device 40 to rotate polishinghead 20. In one example embodiment, polishing head 20 comprises aplurality of flap assemblies 21 attached to a shaft 22 extending atleast partially upward through the center of polishing head 20.

In the example embodiment shown in FIG. 1, shaft 22 extends through anaxial bore (not shown) in housing 31, and protrudes out of the bottom ofhousing 31. The bore in housing 31 acts to support and guide shaft 22during rotary motion of shaft 22. The protruding portion of shaft 22 maybe coupled to chuck 41 of rotary power device 40. In one example, rotarypower device 40 is a cordless portable drill. Alternatively, cordedelectric drills or air driven rotary devices may be used. Folding handle32 is pivotally attached to housing 31 by a pin 33. As shown, handle 32may be folded around housing 31 in position 32′, or may be extended asshown. When extended, handle 32 may provide better support and controlof the polishing tool as the polishing head interacts with a surface tobe polished.

Housing 31 may be made of a plastic material, a metal material, or acombination of a plastic material and a metal material. Likewise, shaft22 may be made from a plastic material, a metal material, or acombination of a plastic material and a metal material. Suitable plasticmaterials may comprise polyethylenes, polycarbonates, nylons,polypropylenes, polyvinylcarbonates, polyurethanes, and polyethyleneterephthalate (PET). Suitable metal materials may comprise steel,aluminum, aluminum alloys, brass, and bronze.

In another embodiment, see FIG. 2, polishing tool 110 comprises apolishing head 120 coupled to a handle assembly 130. Polishing head 120comprises a plurality of flap assemblies 21 attached to shaft 122. Shaft122 extends below polishing head 120 and is sized to attach to handleassembly 130 at coupling 27. Coupling 27 connects shaft 122 to handleshaft 28. Handle shaft 28 extends through an axial bore (not shown) inhousing 31. Handle shaft 28 may be attached to rotary power device 40 bychuck 41. Shaft 122 and handle shaft 28 may be made from plasticmaterials, metal materials, and combinations thereof as previouslydescribed. Folding handle 32 is pivotally attached to housing 31 by apin 33. As shown, handle 32 may be folded around housing 31 in position32′, or may be extended as shown. When extended, handle 32 may providebetter support and control of the polishing tool as the polishing headinteracts with a surface to be polished.

FIG. 3A shows a view of polishing head 20. It will be appreciated thatthe difference between polishing head 20 and polishing head 120 is thedifference in length of shafts 22 and 122. The following description ofthe arrangement and construction of the plurality of flap assemblies 21applies to both polishing head 20 and polishing head 120. Referring alsoto FIGS. 3B-5, each flap assembly 21 may comprise an upper materiallayer 51 and a lower material layer 53 with two stiffener elements 52located between upper material layer 51 and lower material layer 53. Inone embodiment, the width W of upper material layer 51 and lowermaterial layer 53 is in the range of about 4.5 inches (114 mm) to about5 inches (127 mm). FIG. 4 shows an exploded partial view of one exampleof the construction of flap assembly 21. FIG. 5 is a cross-section of aflap assembly showing upper and lower material layers with stiffenerelements. In FIG. 4, only one stiffener element 52 and a cutaway uppermaterial layer 51 are shown for clarity above a full lower materiallayer 53. Upper material layer 51 and lower material layer 53 maycomprise a cloth material and/or a foam material. In one embodimentupper material layer 51 and lower material layer 53 comprise a polyesterand polyamide microfiber fabric. Alternatively, natural fiber materialsmay be used, including felt, wool, mohair, cotton, and linen. In oneexample, stiffener element 52 may be made of an elastomer or plasticfoam material having a stiffness greater than the stiffness of uppermaterial layer 51 and lower material layer 53. Stiffener element 52provides sufficient rigidity to force upper material layer 51 and lowermaterial layer 53 of flap assembly 21 to extend substantially radiallyoutward from shaft 22 during rotation of polishing head 20.Alternatively, at least one unstiffened material layer (not shown) maybe interleaved between flap assemblies 21.

In one embodiment, upper material layer 51 and lower material layer 53may be attached to stiffener 52 by any suitable technique, for example,by an adhesive, by stitching, or a combination of adhesive andstitching. As shown in FIGS. 4 and 5, stiffener element 52 is locatedinboard from the edge of material layers 51 and 53, such that apredetermined length L of unsupported material makes first contact withthe workpiece surface. The flexible, unsupported material may enhancethe polishing action of the material when the material interacts withthe workpiece surface. There is a gap H between the stiffeners 52 ineach flap assembly. Gap H provides access for stitching multiple layerstogether as shown in FIG. 3B and FIG. 6, where a plurality of flapassemblies 21 are stacked and stitched together along stitch lines A andB that may extend along the length of upper material layer 51 and lowermaterial layer 53. The stitched stack allows for insertion of shaft 22between two flap assemblies 21, see FIG. 3B. The attached flapassemblies may be attached to shaft 22, for example, using an adhesive.In other embodiments, upper material layer 51 and lower material layer53 may comprise multiple layers of material attached together byadhesive and/or stitching.

The upper and lower material layers 51 and 53 may be shaped havingvarying widths such that both small and large workpiece features may bepolished using the same polishing head. For example, FIG. 4 shows asubstantially bullet shaped layer having a large relatively constantwidth section P1 for polishing relatively flat surfaces, and a smallertapered width section P2 for polishing smaller surfaces and/or cavities.In use on automotive surfaces, for example, the large relativelyconstant width section P1 may be used for polishing, for example,fenders, hoods, and trunk lids. The smaller tapered width section P2 maybe more useful for polishing, for example, around door handles and/orwithin wheel spokes.

FIG. 7 presents another example shape for a material layer 60 for thepolishing head wherein the edges S1 and S2 taper substantially linearlyfrom a relatively small width at each end to a relatively large width Wnear the center of each side.

FIG. 8A shows another example shape for a material layer 70 for thepolishing head. Layer 70 comprises a main section 71 for polishing largesurfaces, and a bulbous tip 72 for polishing small areas and openings.In the example embodiment shown, there are at least three polishingareas S3, S4, and S5 of differing shapes for polishing a variety ofdifferent surfaces on a workpiece. In FIG. 8A, bulbous tip 72 issubstantially round having a radius R. In one embodiment, the radius Ris about 0.5 inch (13 mm). In another embodiment, see FIG. 8B, a bulboustip 75 may have an elliptical shape.

FIGS. 9A and 9B show another example embodiment of a flap assembly 110that may be used with polishing heads 20 and/or 120, describedpreviously. Flap assembly 110 may comprise an upper material layer 90and a lower material layer 91 with stiffener elements 95 located betweenupper material layer 90 and lower material layer 91. In one example,material layers 90 and 91 may comprise a polyester and polyamidemicrofiber fabric, a felt material, a wool material, a mohair material,a cotton material, a linen material, and combinations thereof. Stiffenerelements 95 may comprise an elastomer or a plastic foam material havinga stiffness greater than the stiffness of upper material layer 90 andlower material layer 91. In one example, upper material layer 90 andlower material layer 91 may comprise a textured pattern 98. For example,textured pattern 98 may be formed into the material. Textured pattern 98may comprise a hexagonal pattern, as shown. Alternatively, texturedpattern 98 may comprise any suitable geometric pattern.

Upper material layer 90 and lower material layer 91 may be attached tostiffeners 95 by any suitable technique, for example, by an adhesive, bystitching, or a combination of an adhesive and stitching. A plurality offlap assemblies 110 may be assembled together using the techniquesdescribed previously with reference to FIG. 3B and FIG. 6. The assembledflap assemblies may be attached to shaft 22 or shaft 122 as describedpreviously.

In another example, referring to FIG. 10, a flap assembly 121 may have acutout 96 located on one side of a centerline 94 of an upper materiallayer 93 such that a foam stiffener element 95 is accessible throughcutout 96. The placement of cutout 96 on one side allows the foamstiffener element material to be accessed for polishing a surface whenthe rotary power device is driven in a first direction, and the materiallayer is accessible for buffing when the rotary power device is drivenin an opposite second direction. Any number of such cutout flapassemblies 121 may be assembled together, as described previously. Inone example, stiffener element 95 may comprise an open cell plastic foammaterial that holds a polishing compound, for example a polishing wax,during the polishing process. It will be understood that a similarcutout may be formed in lower material layer 91.

FIG. 11 shows one example of material layers 90 or 91 having a texturedpattern, for example, a textured pattern 98 formed in the materiallayer. In the example shown, a hexagonal pattern may be formed in thematerial layer. In one example, an outline perimeter 97 may be raisedwith respect to a hexagonal surface 99. Alternatively, hexagonal surface99 may be raised with respect to outline perimeter 97. The portion thatis not raised, that is the lower feature, may provide a collection areafor dirt and/or used polishing compound collected on the material layersduring the polishing and/or buffing process. As indicated previously,any suitable textured geometric pattern may be used.

FIG. 12 shows an example of an upper or lower material layer 100 thathas an internally arched lower edge 102 that may provide for increasedhand clearance when used in an assembled polishing head, for examplepolishing heads 20 and 120, described previously.

The foregoing description is intended for illustration and should not beconstrued as limiting the scope of the invention in any way. Thoseskilled in the art will recognize many variations that may be madewithout departing from the scope of the disclosed invention.

1. An apparatus for polishing a surface comprising: a polishing head comprising a plurality of flap assemblies; and a shaft attached to the plurality of flap assemblies for rotatably driving the polishing head.
 2. The apparatus of claim 1 wherein the flap assembly comprises an upper material layer and a lower material layer with at least one stiffener element between the upper material layer and the lower material layer.
 3. The apparatus of claim 2 wherein the at least one stiffener element is smaller than the upper material layer and the lower material layer such that at least an unsupported length L of the upper material layer and the lower material layer extend outward from the at least one stiffener element.
 4. The apparatus of claim 2 wherein the upper material layer and the lower material layer comprise a microfiber material.
 5. The apparatus of claim 2 wherein the stiffener element comprises a foam material.
 6. The apparatus of claim 1 further comprising a handle assembly acting cooperatively with the shaft to support the polishing head.
 7. The apparatus of claim 6 wherein the handle assembly comprises a housing and a folding handle pivotally attached to the housing.
 8. The apparatus of claim 6 wherein the shaft extends through the handle assembly.
 9. The apparatus of claim 6 further comprising a handle shaft extending through the housing coupled to the shaft.
 10. The apparatus of claim 2 wherein the upper material layer and the lower material layer each have a shape comprising a first width at a first section and a tapering width section.
 11. The apparatus of claim 2 wherein the upper material layer and the lower material layer comprise a main section and a bulbous tip.
 12. The apparatus of claim 2 wherein at least one of the upper material layer and the lower material layer has a cutout extending through the at least one of the upper material layer and the lower material layer.
 13. The apparatus of claim 2 wherein the at least one of the upper material layer and the lower material layer comprises a textured surface.
 14. The apparatus of claim 2 wherein the upper material layer and the lower material layer each comprise an internally arched lower edge.
 15. The apparatus of claim 2 wherein the stiffener element comprises an open cell foam material. 